Process for preparing adhesive using planetary extruder

ABSTRACT

A continuous process for preparing a pressure sensitive adhesive using a planetary roller extruder is described. The continuous process includes introducing at least one non-thermoplastic elastomer into a planetary roller extruder and initially compounding the non-thermoplastic elastomer in the planetary roller extruder to form an initially masticated non-thermoplastic elastomer. Then, a solid raw material, a liquid material, or both are introduced into the initially masticated non-thermoplastic elastomer in the planetary roller extruder, and subsequent compounding of the initially masticated non-thermoplastic elastomer with these additional components occurs to form an adhesive composition.

REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.13/337,521, filed Dec. 27, 2011, which is a continuation of U.S.application Ser. No. 11/702,282, filed Feb. 5, 2007, now U.S. Pat. No.8,110,612, which is a continuation of U.S. application Ser. No.10/997,827, filed Nov. 24, 2004, now U.S. Pat. No. 7,476,416, whichclaims the benefit of U.S. Provisional Application No. 60/524,505.

FIELD OF THE INVENTION

The present invention relates to a continuous, low-temperature processfor the mastication and compounding of non-thermoplastic elastomers withtackifying resins and may include one or more of the following:thermoplastic elastomers, extenders, plasticizers and oils, activators,anti-degradents, crosslinking agents, colorants, solvents, and foamingagents. In one aspect of the invention, the adhesive may be applieddirectly to a web-form material.

The general purpose of the invention is to provide a method forproducing a self adhesive composition by mastication ofnon-thermoplastic elastomers in a planetary roller extruder (PRE). Inone embodiment mastication is achieved through the use of doubletransversal or “back-cut” planetary spindles, in combination withfull-flight planetary spindles to produce an adhesive that can beapplied to a web-form material using a slot die.

BACKGROUND OF THE INVENTION

Pressure sensitive adhesive compositions are blends of several rawmaterials including elastomers, resins, plasticizers and other additivessuch as antioxidants, fillers, pigments, etc. Since these ingredientsmust be blended in the proper ratio to obtain the adhesive having thedesired properties, the raw materials are typically blended with amechanical mixer under controlled conditions as part of a batch-wiseprocess to obtain a thoroughly mixed product having the appropriaterelative amounts of the raw materials.

Planetary roll extruders have been known and have typically been used inprocessing of thermoplastics such as PVC, for example, where they wereused primarily to supply the downstream units such as, for example,calenders or roll mills. Planetary roll extruders have typically beenused to process heat-sensitive compounds with a minimum of degradationbecause thin layers of compound can be exposed to large surface areasthereby resulting in effective heat exchange, mixing and temperaturecontrol. Planetary roll extruders are available in various designs andsizes. The diameters of the roll cylinders, depending on the desiredthroughput, are typically between 70 mm and 500 mm.

Planetary roll extruders generally have a filling section and acompounding section. The filling section typically includes a conveyingscrew to which certain raw materials are fed continuously. The conveyingscrew then passes the material to the compounding section. Thecompounding section includes a driven main spindle and a number ofplanetary spindles which rotate around the main spindle within a rollcylinder with internal helical gearing. The rotary speed of the mainspindle and hence the rotational speed of the planetary spindles can bevaried and is one parameter to be controlled during the compoundingprocess. The materials are circulated between the main and planetaryspindles, or between the planetary spindles and the helical gearing ofthe roll section, so that under the materials are dispersed to form ahomogeneous composition.

The number of planetary spindles rotating in each roll cylinder can bevaried and thus adapted to the requirements of the process. The numberof spindles influences the free volume within the planetary rollextruder, the residence time of the material in the process, and alsodetermines the surface area for heat and material exchange. By way ofthe dispersive energy introduced, the number of planetary spindles hasan influence on the result of compounding. Given a constant diameter ofroll cylinder, a larger number of spindles permit better homogenizationand dispersion or, respectively, a greater product throughput.

The maximum number of planetary spindles installable between the mainspindle and the roll cylinder depends on the diameter of the rollcylinder and on the diameter of the planetary spindles used. When usingrelatively large roll diameters, as required for obtainingproduction-scale throughputs, and/or relatively small diameters for theplanetary spindles, the roll cylinders can be equipped with a relativelylarge number of planetary spindles. With a roll diameter of D=70 mm,typically up to seven planetary spindles are used, whereas with a rolldiameter of D=200 mm ten, for example, and a roll diameter of D=400 mm24 for example, planetary spindles can be used. However, these examplesare in no way limiting to those skilled in the art. For example, if thediameter of the main spindle is smaller relative to a larger mainspindle, the number of planetary spindles can be increased.

SUMMARY OF THE INVENTION

The present invention is directed to a process for preparing an adhesiveusing a modified planetary roller extruder. The process in accordancewith one aspect of the invention includes introducing primary rawmaterials including a non-thermoplastic elastomer into a feeding sectionof the modified planetary roller extruder, conveying the raw materialsfrom the feeding section to a compounding section of the modifiedplanetary roller extruder, mixing the primary raw materials in thecompounding section, producing a homogeneous adhesive composition andapplying the adhesive composition to a web-form material. Thecompounding section of the modified planetary roller extruder includes amain spindle surrounded by and intermeshed with a plurality of planetaryspindles at least one of which is a double transversal mixing spindlehaving a plurality of back-cut helical flights.

In accordance with another aspect of the invention, the modifiedplanetary roller extruder is used to produce an adhesive composition.The process in accordance with this aspect of the invention includescontinuously metering into a planetary roller extruder primary rawmaterials of an adhesive composition comprising a non-thermoplasticelastomer and a tackifying resin, continuously mixing the raw materialsin a compounding section of the planetary roller extruder to form ahomogeneous adhesive composition wherein the compounding sectionincludes a main spindle surrounded by and intermeshed with a pluralityof planetary spindles wherein at least one of the planetary spindles isa double transversal mixing spindle having a plurality of back-cuthelical flights, and continuously discharging the homogeneous adhesivecomposition from the extruder. In accordance with certain embodiments,the self-adhesive composition may be applied to a web-formed materialusing an applicator unit such as a slot-die applicator unit andsubsequently crosslinked.

In accordance with another aspect of the invention, the elastomer ismasticated such that M_(w) is reduced to less than 1,000,000 as measuredby GPC. In other aspects of the invention, the elastomer may bemasticated to cause a reduction in M_(w) of more than about 50%, moreparticularly more than about 80%, relative to the original M_(w) for theelastomer.

BRIEF DESCRIPTION OF THE DRAWINGS

An exemplary embodiment of the invention is explained in more detailbelow with reference to the drawings in which:

FIG. 1 is a longitudinal sectional view of a planetary roller extruderin accordance with one aspect of the present invention;

FIG. 2 is an enlarged view of an exemplary double transversal mixingspindle;

FIG. 3 is a cross-sectional view of a dosing ring from the planetaryroller extruder in FIG. 1;

FIG. 4 is cross-sectional view of a slot die coater;

FIG. 5 is a longitudinal sectional view of a planetary roller extruderand slot die coater in accordance with one aspect of the presentinvention; and

FIG. 6 is a cross-sectional view of the planetary roller extruder inFIG. 1 along line 6-6.

DETAILED DESCRIPTION OF THE INVENTION

All documents cited are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention.

Turning now to the drawings, and referring initially to FIG. 1, aplanetary roller extruder in accordance with one embodiment of thepresent invention is illustrated and generally designated by thereference 10. It will be appreciated that the planetary roller extrudersystem 10 is illustrated in diagrammatic form in order to explain itsoperation in easily understandable manner. However, in actual practice,the shape and size of the system 10 might be substantially differentfrom that illustrated and yet still be within the scope of the claimsset forth herein.

The planetary roller extruder system 10 includes a feeding section 12and a compounding section 14. The primary adhesive raw materials areadded into the feed throat 16 and metered onto the conveying screw 18 ofthe filling section 12. As used herein, the term “primary raw materials”refers to those materials of the adhesive formulation added into thefeed section 12 of the planetary roller extruder 10. Primary rawmaterials may include, but are not limited to, elastomers, resins,extenders, activators, anti-degradents, and crosslinking agents. Thescrew 18 conveys the primary raw materials into the compounding section14. The compounding section 14, as illustrated in FIG. 1, includes fourplanetary roller barrel sections 20 a, 20 b, 20 c and 20 d separated bydosing rings 22 a, 22 b and 22 c. Each roller barrel section 20 includesa 45° helical toothed cylinder 24, a 45° helical toothed main spindle 26and a plurality of 45° helical toothed planetary spindles 28, 30. Thehelical gearing can have any suitable angle, for example, an angle of 10to 60°, more particularly somewhat greater than 20° may be useful. Inaccordance with the certain aspects of the present invention, at leastone of the roller barrel sections 20 includes a double transversalplanetary spindle 28. The present invention is not limited to the use ofdouble transversal planetary spindles. Other spindle configurations thatprovide the desired levels of mixing can also be used.

The maximum number of planetary spindles 28, 30 is a function of thediameter of the main spindle 26 and the helical toothed cylinder 24. Theplanetary spindles 28, 30 can exhibit many different tooth geometries,e.g., full helical flights (Planetspindel) 30, double transversalhelical flights (also known as back-cut spindles or Noppenspindel) 28,or zoned helical flights (Igelspindel), etc. The number of planetaryspindles chosen and their geometries (e.g., open vs. full flight) can bemanipulated in such a way as to influence the dynamic discharging effectof each roller barrel section 20 and the discharging differentialbetween sections. Additionally, the gap between the dosing ring 22 andthe main spindle 26 can be changed to vary the dynamic dischargingeffect of each barrel section 20 and the discharging differentialbetween the barrel sections 20.

A standard planetary spindle 30 is represented by a cylinder in whichgrooves or flights have been cut at 45° angles to the spindle axis, thesame angle as the main spindle flights. The planetary spindles ride inthe main spindle flights and this design yields identical surface speedsof the planetary spindles 28, 30 and the main spindle 26. There is a gapbetween the main and planetary spindles which is filled with processmaterial and the net result is that near zero-shear distributive anddispersive mixing can occur between the main spindle 26, the planetaryspindles 28, 30, and the barrel wall 24.

Another net result of the 45° angle cut into the planetary and mainspindles is a positive pressure, a forwarding motion imparted on theprocess material. A variation which yields less pressure, more slippage,less forwarding motion, longer residence time and hence greater mixingis the use of or double transversal spindles 28 (also known asnoppenspindles or back-cut spindles).

Double transversal planetary spindles 28 are spindles having openings inthe flights that permit material to pass between the wall of the barrel24 and the main spindle 26 and slow the rate with which material passesthrough the planetary roller extruder system 10. One example of a doubletransversal spindle 28 is a so-called porcupine spindle. A particularexample of a double transversal spindle 28 is shown in detail in FIG. 2,back cut openings 32 increase residence time and improve mixing. Thedesign of a double transversal spindle 28 is a variation of the standardplanetary spindle, with the addition of channels cut into the 45° angledflights. The angle of these back cut channels can range from about45-135° relative to the spindle flights, more particularly from about75-105°, and in accordance with certain aspects of the invention theback cut channels may be at an angle of about 90°. The number and depthof these channels may also be varied and can be defined in moresimplistic terms by the following: [(total channel area cut into thespindle flights/total area of spindle flights)×100%]. This value mayrange from about 10-90%, more particularly from about 40-60%, and incertain embodiments of the invention the value may be about 50%.Planetary roller extruders having double transversal spindles 28 arecommercially available from Rust-Mitschke-Entex. By adjusting the numberof full flight 30 and open or double transversal spindles 28, the ratewith which material passes through the planetary roller extruder andhence the amount of mastication that is done on the material can becontrolled.

Conventional planetary roller extruders contain at least 3 and cancontain up to 24 spindles depending on the diameter of the cylinder andprocess design. Of course, one of skill in the art would realize that agreater number of planetary spindles could be used depending on thespecific dimensions and construction of the extruder. In one embodimentof the invention, a planetary roller extruder 10 having a 70 mm diametercylinder having 6 spindles 28, 30 is used. In accordance with certainaspects of the invention, the double transversal spindles 28 account formore than 20%, more particularly more than 50%, of the number ofplanetary spindles 28, 30 in the planetary roller extruder 10. FIG. 6shows a cross-section for a planetary extruder in accordance with aparticular embodiment of the invention that includes four (4) doubletransversal planetary spindles 28 and two (2) full flight spindles 30.

The rotation of the main spindle 26 causes the planetary spindles 28, 30to be set in rotational movement, as a result of the helical gearing ofthe main spindle 26 interacting with the helical gearing of theplanetary spindles 28, 30.

The planetary spindles 28, 30 also mesh with the internal gearing of thecylinder section 24. The helical gearing of the main spindle 26, theplanetary spindles 28, 30 and the cylinder section 24 conveys the rawmaterials to be compounded in the direction of the discharge orifice 34.

The term “secondary raw materials” as used herein refers to rawmaterials or solvents introduced into the compounding section 14 of theplanetary roller extruder 10. Secondary liquid materials, such as liquidelastomers, molten resins, oils, solvents, etc., can be introduced intothe compounding section 14 via injection nozzles (not shown) through thedosing ring 22 assemblies. As shown in FIG. 3, the dosing rings 22include radially extending bores 23 that allow for metered addition ofliquids to the compounding section 14. In accordance with one embodimentof the invention, the process involves the feeding of solvent into thecompounding section 14 of the planetary roller extruder 10 via thedosing rings 22.

Secondary solid raw materials can be added to the compounding section 14through a side feeder 36 or twin screw dosing units 38. The twin screwdosing units 38 are typically positioned perpendicular to the axis ofthe compounding section 14 and are typically located near the beginningof the compounding section directly adjacent to the dosing ring 22 a.The twin screw dosing units 38 can be employed to introduce solidcomponents such as thermoplastic elastomers, resins, extenders,activators, anti-degradents, crosslinkers, etc., to the individualroller barrel sections 20.

Another embodiment of the invention involves coating the self-adhesivecomposition on a web-form material, where the coating of the web-formmaterial may be carried out using any of a variety of coating techniquesincluding, but not limited to, slot-die coating, roll-over-roll coating,reverse roll and knife-over-roll coating. In accordance with certainembodiments of the present invention, the adhesive composition isapplied to the web-form material using a slot-die applicator unit.Particularly useful methods for applying the adhesive composition to theweb-form material include slot-die coating using a rotating lip die or afixed lip contact die. One particular slot die unit that can be used isa rotating lip die having a spindle that trails the die lip. One exampleof such a die is commercially available from SIMPLAS and is shown inFIG. 4. Rotating lip die 40 includes an inlet 42 for receiving theadhesive composition from the extruder 10. As shown in FIG. 5, theadhesive composition is continuously conveyed from the extruder 10 tothe rotating lip die applicator 40 to be applied to a web-form materialthrough slot 44. The rotating lip die applicator 40 further includes arotating spindle 46 at the trailing edge of the die lip that improvescoating properties of the applied adhesive. Adjustable bolts 48 on therotating lip die applicator 40 enable the operator to easily adjust thelip opening and control the adhesive coating thickness.

In accordance with another aspect of the present invention, theself-adhesive composition may be crosslinked. More specifically thecoated adhesive composition may be crosslinked with the aid of electronbeams or UV rays by means of ionizing radiation, such as electron beams,for example, so that the resultant self-adhesive tape becomesshear-resistant and temperature-stable. UV rays as well can be used forcrosslinking, in which case appropriate UV promoters, for example suchas Ebecryl 140 from UCB, must be added to the self-adhesive composition.Chemical and/or thermally induced crosslinking may also be used.

The non-thermoplastic elastomer may be chosen from the group of thenatural rubbers or of the synthetic rubbers or of any desired blend ofnatural rubbers and/or synthetic rubbers, it being possible to choosethe natural rubber or rubbers in principle from all available grades,such as, for example, crepe, RSS, ADS, TSR, SIR 10, SIR 5L or CV grades,depending on the required purity and viscosity level, and it beingpossible to choose the synthetic rubber or rubbers from the group of therandomly copolymerized styrene-butadiene rubbers (SBR), butadienerubbers (BR), synthetic polyisoprenes (IR), butyl rubbers (IIR),polyisobutylene rubber, halogenated butyl rubbers (XIIR), acrylaterubbers (ACM), ethylene vinyl acetate copolymers (EVA) andpolyurethanes, and/or blends thereof.

Thermoplastic elastomers with a weight fraction of from 1 to 100% byweight, based on the total non-thermoplastic elastomer content, can beadded to the non-thermoplastic elastomers. As representatives, mentionmay be made at this point in particular of the highly compatiblestyrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS), styreneisoprene butadiene styrene (SIBS) grades as well as SEBS, and SEPS, andany combination thereof.

Tackifier resins which can be used are, without exception, all tackifierresins that can function as tackifiers in the formulation. Tackifierresins may be present in the adhesive composition at from 40% to 200%weight fraction based on elastomer. Representatives that may bementioned include the rosins, their disproportionated, hydrogenated,polymerized and esterified derivatives and salts, the aliphatic andaromatic hydrocarbon resins, terpene resins and terpene-phenolic resins.Typical resins include partially or fully hydrogenated wood, gum, ortall oil rosins, esterified wood, gum or tall oil rosins, alpha and betapinene resins, and polyterpene resins. More specifically, resins usefulherein include C5 hydrocarbon resins, C9 hydrocarbon resins and mixturesthereof. Coumarone indene and alpha-methyl styrene resins can also beused. The resins can be introduced in both solid and molten form. Anydesired combinations of these and other resins can be used in order toadjust the properties of the resultant adhesive composition inaccordance with what is desired. Reference may be made expressly to thedepiction of the state of knowledge in “Handbook of Pressure SensitiveAdhesive Technology” by Donatas Satas (van Nostrand, 1989).

Typical extenders include clays, calcium carbonate, talc, and aluminumhydrates. Typical activators include zinc oxide, zinc chloride,magnesium chloride and magnesium oxide. Typical anti-degradents includeantioxidants (AO), ultraviolet absorbers (UVA), and ultravioletstabilizers (UVS). Typical opacifiers and colorants include, but are notlimited to, titanium dioxide and other various metal pigments known tothose skilled in the art.

Typical solvents are non-polar aromatics and aliphatics such as acetone,toluene, hexane, heptane, and blends thereof. When a highly foamedadhesive is desired, the solvent content of the adhesive may beincreased. This aspect of the disclosure overcomes the problemstypically encountered with typical hot melt adhesives that experienceproblems caused by the higher densities and smooth, non-extensiblesurfaces of extruded adhesives which result in a low ratio of tack toadhesion in the finished adhesive. Solvents, when present in theformulation, may be used in any amounts up to about 70%, moreparticularly up to about 50%, by weight of the adhesive composition.Typical liquid elastomers are low molecular weight natural rubber andlow molecular weight synthetic polyisoprene and polybutene rubbers.Typical oils can be paraffinic, isoparaffinic, napthenic, aromatic, orpolyaromatic. Examples of foaming agents include Cellogen foaming agentsand gases.

Plasticizers which can be used are all plasticizing substances knownfrom adhesive tape technology. Examples of useful plasticizers include,but are not limited to, the paraffinic and naphthenic oils,(functionalized) oligomers such as oligobutadienes and oligoisoprenes,liquid nitrile rubbers, liquid terpene resins, animal and vegetable oilsand fats, phthalates, and functionalized acrylates.

Simply stated, some advantages of certain embodiments of the newinvention/method include; 1) purposeful, effective, and efficientmastication of non-thermoplastic elastomers, 2) the introduction ofvarious solid raw materials into the compounding section, 3) theintroduction of solvent into the compounding section, and 4) the use ofslot-die coating technology to achieve an adhesive coated web-formmaterial with a unique balance of converged panel adhesion and quickstick properties.

The purposeful mastication of non-thermoplastic elastomers isaccomplished as the elastomers are forced with the single-screw from thefeeding section between the dosing ring and the main spindles into thecompounding section, where it is intensively mixed and subsequentlymasticated. The degree of mastication is further enhanced through theuse of double transversal planetary spindles. Another factor thataffects the amount of mastication is the internal diameter of the stopring. By narrowing the gap between the stop ring or dosing ring and thespindle, more mastication can be performed. Mastication of thenon-thermoplastic elastomer translates into more efficient compoundingof the elastomer with other solid and liquid materials, yields thepotential for a greater ratio of tack to adhesion in the finishedadhesive and yields a finished adhesive with lower viscosity that is notlimited to being coated via a multiple roll applicator unit (calender).This provides an opportunity to employ more-prevalent, or existingcoating equipment, as opposed to purchasing a multiple-roll coatingunit.

In accordance with one aspect of the invention, the elastomer ismasticated such that M_(w) is reduced to less than 1,000,000 as measuredby GPC. In other aspects of the invention, the elastomer may bemasticated to cause a reduction in M_(w) of more than about 50%, moreparticularly more than about 80%, relative to the initial M_(w) for theelastomer. The initial molecular weight refers to the molecular weightof the non-thermoplastic elastomer as it is being introduced into theplanetary roller extruder. As such, the initial molecular weight mayalready have been reduced as a result of preprocessing of the elastomeras compared to the molecular weight for the unprocessed elastomer.Therefore, the reduction in molecular weight referred to herein is basedon the reduction in molecular weight obtained by processing on theplanetary roller extruder. The reduction in molecular weight asdescribed herein is calculated by Formula I:% Reduction=(M _(w(initial)) −M _(w(final)))/M _(w(initial))×100  (I)

The introduction of various solid raw materials into the compoundingsections has several advantages. First, all solid materials do not haveto be introduced all at once in the feeding section of the planetaryroller extruder, i.e., they can be dosed in one or more of the rollerbarrel sections of the compounding section. This gives the elastomermore time to be masticated prior to the addition of solid raw materialsand increases the mixing efficiency of the planetary roller extruder.Second, solid resin, as opposed to molten resin can be introduced intothe compounding section. The solid resin has a viscosity that moreclosely resembles the elastomer, when compared to molten resin. As aconsequence, the addition of solid (as contrasted with liquid) resinfurther enhances mixing efficiency, whereas molten resin tends to act asa lubricant and retards mixing efficiency. Additionally, the solid resinhas a specific heat which affords it the ability to act as a heat sink,i.e. take heat away from the process, thereby minimizing the temperatureof the melt during the compounding process. Conversely, molten resinincreases the temperature of the melt in the compounding process.

The introduction of solvent into the compounding sections has severaladvantages. First, small amounts (e.g., typically 10 to 20% by weightbut amounts up to 50% could feasibly be used) of solvent, introduced tothe adhesive through several dosing rings, enhances mixing efficiency,i.e. maintains homogeneity, while significantly lowering the viscosityof the finished adhesive. The solvent is readily absorbed by theadhesive composition and the incorporation of solvent lowers theresultant homogeneous adhesive's viscosity to the point that itsapplication to a web-form material is not restricted to a multi-rollapplicator unit (calender). Rather, the lower-viscosity adhesive can nowbe applied to web-form material via slot-die, reverse roll,roll-over-roll, knife-over-roll, or any number of traditional adhesiveapplication techniques including the use of multi-roll applicators. Thesubsequent liberation of the solvent from the adhesive that has beenapplied to the web-form material affords the ability to affect numerousadhesive surface geometry profiles, i.e. degrees of foaming, in theadhesive film. Subsequently, the performance properties of the adhesivefilm can be further manipulated, i.e. in addition to degree of elastomermastication and formulation.

The use of a slot-die for coating adhesives to web-form material hasparticular advantages over a multi roll applicator unit (calender).Web-form adhesive coating speeds, when employing multi roll applicatorunits (calenders), are typically limited to 300 meters per minute.However, the use of slot-die coating technology, particularly whenemployed in conjunction with lower-viscosity, high-solids adhesives,e.g. 80-90%, as opposed to higher-viscosity, 100% solids adhesives, isof particular interest, as application speeds easily approach 500 metersper minute or more.

The process of the invention permits the production of high-performanceself-adhesive compositions and, especially in conjunction with adownstream coating and crosslinking unit, permits the production ofhigh-performance self-adhesive tapes accompanied by particular costadvantages.

In the first process step, a composition comprising the elastomers andthe known adjuvants required for the production of self-adhesivecompositions, such as extenders, antioxidants, activators, colorants,ageing inhibitors, plasticizers and tackifier resins, is produced in aplanetary roll extruder, the composition having a final temperature ofless than 150° C., typically less than 130° C. and, more particularly,between about 25° C. and 100° C. The overall residence time of thecomposition in the planetary roll extruder will typically not exceedabout three minutes.

In accordance with certain aspects of the invention, the adhesiveformulation from the extruder is applied to a web-form material. Thiscan be done in a particularly effective and advantageous manner using aslot-die applicator unit, especially using a rotating lip slot-dieapplicator unit similar to that shown in FIG. 4.

In accordance with another aspect of the present invention, theself-adhesive composition may be crosslinked using electron beams or UVrays to provide a self-adhesive tape having the desired properties. Forfurther improved performance, or in the case of Electron Beam(EBC)-sensitive carriers, crosslinking can also be carried out by meansof heat-activatable crosslinkers under the effect of temperature. Theheating of the pressure-sensitive adhesive composition that is requiredfor this purpose can be done with the aid of the known techniques,especially with the aid of high-temperature ducts, or else with the aidof infrared lamps, or by means of high-frequency magnetic alternatingfields, examples being HF waves, UHF waves or microwaves.

Crosslinking of the pressure-sensitive adhesive composition can becarried out, furthermore, by means of a combination of ionizingradiation and heat-activatable chemical crosslinkers. The result may bea highly shear-resistant pressure-sensitive self-adhesive composition.EB curing sets the adhesive so that it can be converted while having aresidual latent heat-activatable curing agent available for end useapplication.

For the purpose of heat-induced and/or chemical crosslinking, it ispossible in the process of the invention to use all knownheat-activatable and/or chemical crosslinkers, such as acceleratedsulphur or sulphur donor systems, isocyanate systems, reactive melamineresins, formaldehyde resins and (optionally halogenated)phenol-formaldehyde resins and/or reactive phenolic resins ordiisocyanate crosslinking systems with the corresponding activators,epoxidized polyester resins and acrylate resins, and combinationsthereof.

The crosslinkers are preferably activated at temperatures above 50° C.,in particular at temperatures from 100° C. to 160° C. and, in accordancewith certain embodiments, at temperatures from 110° C. to 140° C. Thethermal excitation of the crosslinkers can also be effected by means ofIR rays or high-energy alternating fields. Some crosslinkers may remainin the composition after curing and, therefore, be available foractivation during the end use application.

Further embraced by the concept of the invention is a self-adhesive tapeproduced with the aid of the pressure-sensitive adhesive composition byapplying the self-adhesive composition to at least one side of amaterial in web form. Depending on the intended use of the adhesivetape, suitable web-form carrier materials for the self-adhesivecompositions processed and produced in accordance with the invention areall known carriers, with or without appropriate chemical or physicalsurface pretreatment of the coating side, and anti-adhesive physicaltreatment or coating of the reverse side. Mention may be made, forexample, of creped and non-creped papers, polyethylene, polypropyleneand mono- or biaxially oriented polypropylene films, polyester, PVC andother films, foam materials in web form, made from polyethylene andpolyurethane, for example, wovens, knits and nonwovens. Finally, theweb-form material can be a material with an antiadhesive coating on bothsides, such as release papers or release films.

The thickness of the self-adhesive composition on the web-form materialcan be between 10 μm and 2000 μm, preferably between 15 μm and 150 μm.Finally, the self-adhesive composition can be applied in a thickness offrom 800 μm to 1200 μm on a release paper. An adhesive-composition layerof this kind, especially after crosslinking, can be used diversely as abacking-less double-sided self-adhesive tape.

The following examples illustrate aspects of the invention, withoutintending to be limiting thereof. It will be appreciated that othermodifications of the present invention, within the skill of those in theart, can be undertaken without departing from the spirit and scope ofthis invention.

EXAMPLES Example 1

Ground Ground Natural Rubber Rubber Adhesive Rubber (Kg/hr) N/A 17.1Resin (Kg/hr) N/A 22.2 TiO₂ + antioxidant (Kg/hr) N/A 0.7 Screw Speed(rpm) N/A 70 Adhesive temp, between barrel N/A 72° C. cylinder 1&2Adhesive temp, between barrel N/A 52° C. cylinder 2&3 Adhesive outlettemperature N/A 86° C. Extruder Residence Time (s) 90 Adhesivehomogeneity No gels Mw (GPC) 4,136,110 802,748 Percent Drop in Mw 80.6%Mw (ThFFF) 3,724,000 691,000 Percent Drop in Mw 81.5%

A standard carton sealing adhesive was produced with the PRE havingthree barrel cylinders, represented by 100 phr natural rubber, 130 phrC5 resin, 2 phr TiO2, and 2 phr antioxidant. The rubber used in thisadhesive was SIR 5L, ground to an average particle size of 8 mm withtalc used as an anti-agglomerating agent. The C5 resin was added inflake form and Antioxidant was introduced as a powder. The adhesive rawmaterials were all added into the feedthroat of a 70 mm PRE. The rawmaterials were subsequently compounded into an adhesive after beingmixed in three 400 mm barrel sections each containing 2 normal and 4double transversal mixing spindles rotating at 70 rpm. The finishedadhesive was determined to be completely homogeneous (gel free).Subsequent molecular weight analysis of the adhesive was completed viagel permeation chromatography (GPC) and thermal field flow analysis(ThFFF). The molecular weight analysis indicated that the natural rubberhad been reduced in molecular weight by approximately 80%.

Example 2

Ground Rubber Adhesive Rubber (Kg/hr) 17.1 Resin (Kg/hr) 22.2 TiO₂,antioxidant (Kg/hr)  0.7 Solvent (toluene) 12.0 Screw Speed (rpm) 65  Adhesive temp, between barrel cylinder 1&2 62° C. Adhesive temp, betweenbarrel cylinder 2&3 57° C. Adhesive outlet temperature 42° C. ExtruderResidence Time (s) 90   Adhesive homogeneity No gels

A standard carton sealing adhesive was produced with the PRE havingthree barrel cylinders, represented by 100 phr natural rubber, 130 phrC5 resin, 2 phr TiO₂, and 2 phr antioxidant. The rubber used in thisadhesive was SIR 5L, ground to an average particle size of 8 mm withtalc used as an anti-agglomerating agent. The C5 resin was added inflake form and antioxidant was introduced as a powder. The adhesive rawmaterials were all added into the feedthroat of a 70 mm PRE. The rawmaterials were subsequently compounded into an adhesive after beingmixed in the first of three 400 mm barrel sections each containing 2normal and 4 double transversal mixing spindles rotating at 65 rpm. Theentire complement of solvent was added via an injection valve insertedinto a dosing ring. The finished adhesive was determined to becompletely solvated and homogeneous (gel free).

Example 3

Pelletized Pelletized Natural Rubber Rubber Adhesive Rubber andAntioxidant (Kg/hr) N/A 14.08 Resin (Kg/hr) N/A 15.88 Filler, ZnO, TiO2(Kg/hr) N/A 7.93 Screw Speed (rpm) N/A 70 Adhesive temp, between barrelN/A 59° C. cylinder 1&2 Adhesive temp, between barrel N/A 53° C.cylinder 2&3 Adhesive outlet temperature N/A 76° C. Extruder ResidenceTime (s) 90 Adhesive homogeneity No gels Mw (GPC) 1,026,671 489,279Percent Drop in Mw 52.3% Mw (ThFFF)   666,000 310,000 Percent Drop in Mw53.5%

A standard masking tape adhesive was produced with the PRE having threebarrel cylinders, represented by 100 phr natural rubber, 115 phr C5resin, 50 phr kaolin clay, 5 phr ZnO, 2.5 phr TiO2, and 2 phrantioxidant. The rubber used in this adhesive was SIR 5L, pre-masticatedand blended with 2 phr antioxidant in a Banbury and subsequentlyprocessed in an underwater pelletizer to yield 8 mm pellets with talcused as an anti-agglomerating agent. The C5 resin was added in flakeform, and the ZnO and TiO2 were introduced as powders. The adhesive rawmaterials were all added into the feedthroat of a 70 mm PRE. The rawmaterials were subsequently compounded into an adhesive after beingmixed in three 400 mm barrel sections each containing 2 normal and 4double transversal mixing spindles rotating at 70 rpm. The finishedadhesive was determined to be completely homogeneous (gel free).Subsequent molecular weight analysis of the adhesive was completed viagel permeation chromatography (GPC) and thermal field flow analysis(ThFFF). The molecular weight analysis indicated that the natural rubberhad been reduced in molecular weight by approximately 50%.

Example 4

Pelletized Rubber Adhesive Rubber and Antioxidant (Kg/hr) 14.08 Resin(Kg/hr) 15.88 Filler, ZnO, TiO2 (Kg/hr) 7.93 Solvent - Toluene (Kg/hr)40.0 Screw Speed (rpm) 144 Adhesive temp, between barrel cylinder 1&264° C. Adhesive temp, between barrel cylinder 2&3 29° C. Adhesive outlettemperature 29° C. Extruder Residence Time (s) 120 Adhesive homogeneityNo gels

A standard masking tape adhesive was produced with the PRE having threebarrel cylinders, represented by 100 phr natural rubber, 115 phr C5resin, 50 phr kaolin clay, 5 phr ZnO, 2.5 phr TiO2, and 2 phrantioxidant. The rubber used in this adhesive was SIR 5L, pre-masticatedand blended with 2 phr antioxidant in a Banbury and subsequentlyprocessed in an underwater pelletizer to yield 8 mm pellets with talcused as an anti-agglomerating agent. The C5 resin was added in flakeform, and the ZnO and TiO2 were introduced as powders. The adhesive rawmaterials were all added into the feedthroat of a 70 mm PRE. The rawmaterials were subsequently compounded into an adhesive after beingmixed in the first of three 400 mm barrel sections each containing 2normal and 4 double transversal mixing spindles rotating at 144 rpm. Thesolvent was added via injection valves inserted into dosing rings, with5 kg/hr added into the dosing ring located between barrels 1&2 and 35kg/hr being added into the dosing ring located between barrels 2&3. Thefinished adhesive was determined to be completely solvated andhomogeneous (gel free).

Example 5

Ground Rubber Adhesive Rubber and Antioxidant (Kg/hr) 14.76 Resin -Feedthroat (Kg/hr) 8.00 Resin - Sidefeeder (Kg/hr) 8.64 Filler, ZnO,TiO2 (Kg/hr) 8.32 Solvent - Toluene - 2/3 (Kg/hr) 11.0 Solvent -Toluene - 3/4 (Kg/hr) 29.0 Screw Speed (rpm) 141 Adhesive temp, betweenbarrel cylinder 1&2 120° C.  Adhesive temp, between barrel cylinder 2&360° C. Adhesive temp, between barrel cylinder 3&4 33° C. Adhesive outlettemperature 21° C. Extruder Residence Time (s) 73 Adhesive homogeneityNo gels

A standard masking tape adhesive was produced with the PRE having fourbarrel cylinders, represented by 100 phr natural rubber, 115 phr C5resin, 50 phr kaolin clay, 5 phr ZnO, 2.5 phr TiO2, and 2 phrantioxidant. The rubber used in this adhesive was SIR 10, ground to anaverage particle size of 8 mm with talc used as an anti-agglomeratingagent. A portion of the C5 resin was added in flake form into thefeedthroat of a 70 mm PRE, along with the ZnO and TiO2 powders. The rawmaterials were subsequently mixed in the first of four 400 mm barrelsections each containing 2 normal and 4 double transversal mixingspindles rotating at 141 rpm. The remaining flake resin was added via asidefeeder located immediately upstream from the first dosing ring andsubsequently mixed in the second barrel section. Solvent was added viainjection valves inserted into dosing rings, with 11 kg/hr added intothe dosing ring located between barrels 2&3 and 29 kg/hr being addedinto the dosing ring located between barrels 3&4. The finished adhesivewas determined to be completely homogeneous and solvated (gel free).

Having described various aspects and embodiments of the invention andseveral advantages thereof, it will be recognized by those of ordinaryskills that the invention is susceptible to various modifications,substitutions and revisions within the spirit and scope of the appendedclaims.

What is claimed is:
 1. A continuous process for preparing an adhesivecomposition comprising: introducing at least one non-thermoplasticelastomer into a planetary roller extruder; initially compounding thenon-thermoplastic elastomer in the planetary roller extruder to form aninitially masticated non-thermoplastic elastomer; introducing a solidraw material, a liquid material, or both into the initially masticatednon-thermoplastic elastomer in the planetary roller extruder; andsubsequently compounding the initially masticated non-thermoplasticelastomer with the solid raw material, the liquid material, or boththereof to form an adhesive composition; wherein the liquid material ispresent and comprises a solvent added to the adhesive composition in anamount of about 10% to about 50% by weight.
 2. The continuous process ofclaim 1, wherein the solid raw material has a specific heat that enablesthe solid raw material to act as a heat sink while subsequentlycompounding with the initially masticated non-thermoplastic elastomer.3. The continuous process of claim 1, wherein the solid raw materialincludes at least one of a thermoplastic elastomer, a tackifier resin,an extender, an activator, an anti-degradent, a crosslinker, anopacifier, and a colorant.
 4. The continuous process of claim 3, whereinthe solid raw material includes at least one thermoplastic elastomer,and the non-thermoplastic elastomer includes at least one naturalrubber, synthetic rubber, or one of both.
 5. The continuous process ofclaim 3, wherein the solid raw material includes at least onethermoplastic elastomer selected from the group consisting ofstyrene-isoprene-styrene, styrene-butadiene-styrene,styrene-isoprene-butadiene-styrene, styrene-ethylene-butadiene-styrene,styrene-ethylene-propylene-styrene, and combinations thereof.
 6. Thecontinuous process of claim 1, wherein the liquid material furthercomprises at least one of an elastomer, a tackifier resin, an oil, and aplasticizer.
 7. The continuous process of claim 1, wherein the solventcomprises at least one non-polar aromatic, one non-polar aliphatic, or ablend thereof.
 8. The continuous process of claim 1, wherein the solventis added in an amount of about 10% to about 20% by weight of theadhesive composition, and the process further comprises applying theadhesive composition to a substrate using a slot-die applicator.
 9. Thecontinuous process of claim 1, wherein the solvent is added in an amountof about 10% to about 20% by weight of the adhesive composition, and theprocess further comprises applying the adhesive composition to asubstrate using a reverse roll, roll-over-roll, or knife-over-rollapplicator.
 10. The continuous process of claim 1, wherein thenon-thermoplastic elastomer in the adhesive composition has a molecularweight less than 1,000,000 as measured by GPC.
 11. The continuousprocess of claim 1, wherein the non-thermoplastic elastomer has aninitial molecular weight when introduced into the planetary rollerextruder and the initial molecular weight is reduced by more than about50% during the process.
 12. The continuous process of claim 1, furthercomprises: introducing a heat-activatable crosslinker into the planetaryroller extruder while initially masticating, after initiallymasticating, or while subsequently masticating the non-thermoplasticelastomer in the planetary roller extruder.
 13. The continuous processof claim 12, wherein the heat-activatable crosslinker is selected fromthe group consisting of an accelerated sulphur or sulphur donor system,an isocyanate system, a reactive melamine resin, a formaldehyde resin, aphenol-formaldehyde resin, a reactive phenolic resin, a diisocyanatesystem, an epoxidized polyester resin, and combinations thereof.
 14. Thecontinuous process of claim 12, wherein the adhesive composition has afinal temperature of about 25° C. to about 100° C.
 15. The continuousprocess of claim 12, wherein the activation temperature of theheat-activatable crosslinker is about 110° C. to about 140° C.
 16. Thecontinuous process of claim 14, wherein the activation temperature ofthe heat-activatable crosslinker is about 110° C. to about 140° C. 17.The continuous process of claim 14, wherein the temperature ismaintained at about 80° C.
 18. The continuous process of claim 13,wherein the heat-activatable crosslinker is the isocyanate system or thediisocyanate system.